Lightweight armor

ABSTRACT

A lightweight armor system senses a shock wave from an explosive and deploys an inflatable barrier before the arrival of shrapnel from the explosion. The sensor is tuned to frequencies associated with shock waves generated by known Improvised Explosive Devices (IEDs). The shock waves travel at between 25,000 and 30,000 feet per second and arrives at a vehicle before the shrapnel generated by the IED. The sensor generates a signal which is amplified and provided to a plurality of initiators in a plurality of nested pods. The nested pods inflate rapidly and form a barrier over areas requiring protection from the shrapnel.

The present application claims the benefit of U.S. ProvisionalApplication Ser. No. 60/816,652 filed Jun. 26, 2006, which applicationis incorporated in it's entirely herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates to vehicle armor and in particular tolightweight inflatable armor.

Growing activities by terrorist groups have often included attacksagainst light vehicles using Improvised Explosive Devices (IEDs). SuchIEDs have inflicted severe casualties and generated a need to increasethe armor on vehicles such as the Hummvee widely in use by the military.Unfortunately, the additional armor has added significantly more weightthan vehicle suspension was designed for resulting in accidents causingfurther injuries.

BRIEF SUMMARY OF THE INVENTION

The present invention addresses the above and other needs by providing alightweight armor system which senses a shock wave from an explosive anddeploys an inflatable barrier before the arrival of shrapnel from theexplosion. The sensor is tuned to frequencies associated with shockwaves generated by known Improvised Explosive Devices (IEDs). The shockwaves travel at between 25,000 and 30,000 feet per second and arrives ata vehicle before the shrapnel generated by the IED. The sensor generatesa signal which is amplified and provided to a plurality of initiators ina plurality of nested pods. The nested pods deploy rapidly and form abarrier over areas requiring protection from the shrapnel.

In accordance with one aspect of the invention, there is providedlightweight armor including a base, inflatable armor pod segments, aninflator circuit, and gas sources. The inflatable armor pod segmentsreside in the base before inflation. The inflator circuit includes ashock wave sensor and a power amplifier electrically connected to thesensor for amplifying a signal from the sensor. The gas source iselectrically connected to the power amplifier and inflates the armorwhen a shock wave is sensed.

In accordance with another aspect of the invention, there is providedlightweight armor including a base for mounting the armor, a pluralityof nested pods, and a deployment circuit. The plurality of nested podsresides in the base before deployment and expands vertically whendeployed. A aramid fiber armor surrounds each pod and aramid fiber clothconnects and covers consecutive pods limiting the vertical travel of thepods to provide an overlap of consecutive pods. The deployment circuitincludes a shock wave sensor and a power amplifier electricallyconnected to the sensor for amplifying a signal from the sensor. A gassource is electrically connected to the power amplifier and provides gasfor each pod for inflating the inflatable armor.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

The above and other aspects, features and advantages of the presentinvention will be more apparent from the following more particulardescription thereof, presented in conjunction with the followingdrawings wherein:

FIG. 1A is a side view of a lightweight vehicle with inflatable armorunits according to the present invention residing on the vehicle body.

FIG. 1B is a front view of the lightweight vehicle with the inflatablearmor units residing on the vehicle body.

FIG. 1C is a top view of the lightweight vehicle with the inflatablearmor units residing on the vehicle body.

FIG. 2A is a side view of the lightweight vehicle with the inflatablearmor units according to the present invention residing on the vehiclebody, with two of the inflatable armor units on the right side of thevehicle deployed.

FIG. 2B is a front view of the lightweight vehicle with the inflatablearmor units residing on the vehicle body, with two of the inflatablearmor units on the right side of the vehicle deployed.

FIG. 2C is a top view of the lightweight vehicle with the inflatablearmor units residing on the vehicle body, with two of the inflatablearmor units on the right side of the vehicle deployed.

FIG. 3A is a detailed side view of the deployed inflatable armor unit.

FIG. 3B is a detailed front view of the deployed inflatable armor unit.

FIG. 3C is a detailed top view of the deployed inflatable armor unit.

FIG. 4A is a cross-sectional view of the deployed inflatable armor unit,taken along line 4A-4A of FIG. 3B.

FIG. 4B is a cross-sectional view of the deployed inflatable armor unit,taken along line 4B-4B of FIG. 3C.

FIG. 5 is a detailed cross-sectional view of the deployed inflatablearmor unit taken along line 4A-4A of FIG. 3B showing an inflator circuitand inflators.

FIG. 6 is a diagram of the inflator circuit.

FIG. 7A is a partial cross-sectional view a the pod assembly beforeactivation.

FIG. 7B is a partial cross-sectional view of the pod assembly afteractivation.

FIG. 8 is a cross-sectional view of the bottom two layers beforeactivation.

FIG. 9 is a pivoting mount for mounting the inflatable armor unit.

FIG. 10 is an end view of the inflatable armor unit.

FIG. 10A is a cross-sectional view of the inflatable armor unit takenalong line 10A-10A of FIG. 10.

FIG. 11 is a time-line for deploying the inflatable armor unit.

Corresponding reference characters indicate corresponding componentsthroughout the several views of the drawings.

DETAILED DESCRIPTION OF THE INVENTION

The following description is of the best mode presently contemplated forcarrying out the invention. This description is not to be taken in alimiting sense, but is made merely for the purpose of describing one ormore preferred embodiments of the invention. The scope of the inventionshould be determined with reference to the claims.

A side view of a lightweight vehicle 10 with inflatable armor units 12,according to the present invention, residing on the right side of thevehicle body is shown in FIG. 1A, a front view of a lightweight vehicle10 with the inflatable armor units 12 residing on the vehicle body isshown in FIG. 1B, and a top view of a lightweight vehicle 10 with theinflatable armor units 12 residing on the vehicle body is shown in FIG.1C. The inflatable armor units 12 may be positioned under windows 14 toprotect the windows from shrapnel generated by an Improvised ExplosiveDevice (IED). The inflatable armor units 12 may also be positioned atother locations, for example, below or above the front grill to protectthe radiator, above wheel wells to protect tires, and next to anylocation requiring protection from shrapnel, for example, to protectotherwise exposed military or civilian personnel.

A side view of a lightweight vehicle 10 with the inflatable armor units12 residing on the vehicle 10 body, and the inflatable armor units 12residing on the right side of the vehicle 10 deployed, is shown in FIG.2A, a front view of the lightweight vehicle 10 with the inflatable armorunits 12 deployed is shown in FIG. 2B, and a top view of a lightweightvehicle 10 with the inflatable armor units 12 deployed is shown in FIG.2C. The inflatable armor units 12 comprise a base unit 13 and deployablepod segments 16. The pod segments 16 are shown deployed and coveringwindows 14 (see FIG. 1A) to protect vehicle occupants.

A detailed side view of the deployable inflatable armor unit 12comprising pod segments 16 and base 13 are shown in FIG. 3A, a detailedfront view of the deployable pod segments 16 and the base 13 are shownin FIG. 3B, and a detailed top view of the deployable pod segments 16and the base 13 are shown in FIG. 3C.

A cross-sectional view of the deployable pod segments 16 and the base 13taken along line 4A-4A of FIG. 3B is shown in FIG. 4A, and across-sectional view of the deployable pod segments 16 and the base 13taken along line 4B-4B of FIG. 3C is shown in FIG. 4B. The pod segments16 comprise a plurality of nested inflatable pods 16 a, 16 b, 16 c, 16d, and 16 e. Each pod 16 a-16 e has it's own gas source (comprising aninitiator and an inflator) 18 a, 18 b, 18 c, 18 d, and 18 erespectively. Each gas source 18 a-18 e translates away from the base 13when the inflatable armor unit 12 is deployed, thereby reducing thedeployment time. The inflatable armor unit 12 preferably inflates to aheight H of approximately three feet. The inflatable armor unit 12preferably comprises between five pod segments and ten pod segments, andthe number of pod segments may be adapted to the present use. The numberof pod segments required is based on achieving a minimum inflation timeand advanced inflators may also serve to reduce the number of podsegments required. The minimum inflation time is determined based on theshock wave speed, sensor speed, and shrapnel speed.

A detailed cross-sectional view of the deployed inflatable armor unit 12taken along line 4A-4A of FIG. 3B showing an inflator circuit 30 and theinflators, is shown in FIG. 5, and a diagram of the inflator circuit isshown in FIG. 6. The inflator circuit 30 comprises a sensor 20, abattery 22, a switch M, and a power transistor 24. The sensor 20 isconnected to the transistor 24 by sensor wires 21. The battery 22 isconnected to the transistor 24 by battery wires 23, with the switch Mserially connected between the battery 22 and the transistor 24 in oneof the battery wires 23. Inflator wires 25 connect the transistor 24 tothe gas sources 18 a-18 e.

A partial cross-sectional view of the pod assembly before activation isshown in FIG. 7A and a partial cross-sectional view of the pod assemblyafter activation is shown in FIG. 7B. Each pod 16 a-16 e in the podassembly 16 comprises an armor plates 52 a-52 e attached to pans 54 a-54e respectively. The armor places 52 a-52 e are preferably made of aramidfibers and other ballistic materials. Aramid fibers or ballistic gradecloth strips 50 a-50 d connect consecutive and cover armor plates 52a-52 e. Prior to activation, the cloth strips 50 a-50 d lay relaxedaround the pod assembly exterior as seen in FIG. 7A, and afteractivation, the kevlar cloth strips are held in tension between theexpanded pod layers. The aramid fiber cloth strips 50 a-50 d connectingand covering consecutive pods 16 a-16 e and limit the vertical travel ofthe pods 16 a-16 e to provide an overlap of consecutive pods 18 a-16 e.As seen in FIG. 7B, the pods 16 a-16 e deploy vertically and arevertically overlapped when deployed.

A cross-sectional view of the bottom two layers before activation isshown in FIG. 8. Gas generating materials 56 a and 56 b reside in thepans 54 a and 54 b respectively. Three or more packings of the gasgenerating material may reside in each pan as needed, depending on theoverall size of the pod assembly 16. The pans 54 a-54 e preferably havechanneled bottoms for added strength as needed.

A pivoting mount 40 for mounting the base 13 is shown in FIG. 9. Thepivoting mount 40 allows the base 13 to be adjusted to provide a maximumcoverage for, for example, a window 14. The base 13 is pivotallyconnected to the pivoting mount 40 at a pivot 42 and indexed by indexpoints 44.

An end view of the inflatable armor unit 12 is shown in FIG. 10 and across-sectional view of the inflatable armor unit 12 taken along line10A-10A of FIG. 10 is shown in FIG. 1A. The inflatable armor unit 12includes an exterior skin 60 covering the top of the base 12 andreaching down over the sides of the base 13. A nylon scrim 62 residesunder the cover skin 60 and extends down inside the base 60. A glass mat64 resides under the scrim 62 and over the pod assembly 16. The exteriorskin 60 may be notched lengthwise to facilitate tearing when the podsare deployed. Foam filling 66 may be provided to fill in a gap betweenthe pods and the base 13.

The bags 16 a-16 e are preferably made from an aramid fiber, a ballisticgrade armor felt, or a ballistic grade fabric such as Kevlar fabric madeby Dupont. An example of a suitable sensor 20 is a model 113A22 sensormade by PCB Piezotronics in Depew, N.Y. An example of a suitableinflator is a model DH-6 Infator made by ARC Automotive, Inc. InKnoxville, Tenn.

A time-line for deploying the inflatable armor 16 is described in FIG.11. The IED is detonated at time 0.0. A shock wave travels away from theIED at between 25,000 and 30,000 feet per second. The shock wave reachesthe vehicle 10, approximately 10 feet from the IED, in approximately 0.4ms. The sensor 20 senses the shock wave in approximately 0.1 ms afterthe shock wave has reached the vehicle 10 (total time 0.5 ms). The gassources 18 a-18 e fire in 0.6 ms after receiving the sensor signal(total time 1.1 ms). The pod segments 16 a-16 e inflate in approximately1.3 ms (total time 2.4 ms). The shrapnel travels at approximately 1000feet per second and thus reaches the vehicle 10 in approximately 10 msin this example.

While the present invention is herein described using deployable pods,an alternative embodiment may replace the pods with air bags.

While the invention herein disclosed has been described by means ofspecific embodiments and applications thereof, numerous modificationsand variations could be made thereto by those skilled in the art withoutdeparting from the scope of the invention set forth in the claims.

1. Lightweight armor comprising: a base for mounting the armor;deployable armor residing in the base before deployment and expandingvertically when deployed; a deployment circuit comprising: a shock wavesensor; and a power amplifier electrically connected to the sensor foramplifying a signal from the sensor; and a motive source for thedeployable armor electrically connected to the power amplifier andproviding.
 2. The lightweight armor of claim 1, wherein the deployablearmor comprises a plurality of vertically overlapping deployable pods.3. The lightweight armor of claim 2, wherein the deployable armorcomprises a plurality of nested pods prior to deployment.
 4. Thelightweight armor of claim 3, wherein the deployable armor comprises aplurality of nested pods and the motive source comprises individualindependent gas sources.
 5. The lightweight armor of claim 3, whereinthe deployable armor comprises a plurality of nested pods comprising apan with a base and sides and armor plates around the sides.
 6. Thelightweight armor of claim 5, wherein the nested pods are connected byballistic grade cloth strips.
 7. The lightweight armor of claim 6,wherein the armor plate are aramid fiber plates and the cloth strips arearamid fiber cloth strips.
 8. Lightweight armor comprising: a base formounting the armor; a plurality of nested pods residing in the basebefore deployment and expanding vertically when deployed; aramid fiberarmor surrounding each pod aramid fiber cloth connecting and coveringconsecutive pods and limiting the vertical travel of the pods to providean overlap of consecutive pods. a deployment circuit comprising: a shockwave sensor; and a power amplifier electrically connected to the sensorfor amplifying a signal from the sensor; and a gas source for each podfor inflating the inflatable armor, the gas source electricallyconnected to the power amplifier.